Method of forming an imaged compound textile fabric

ABSTRACT

The present invention contemplates a method of forming a textile laminate or composite fabric from a plurality of woven fabric layers, with the method contemplating use of a three-dimensional image transfer device to facilitate efficient and commercially viable use of the method. 
     Herein is disclosed a method of forming an imaged textile laminate or composite compound fabric, the fabric having a first textile fabric layer comprising a plurality of interwoven warp and weft yarns and at least one other textile fabric layer, the lamination of the fabric layers and imaging of the construct occurring on a three-dimensional image transfer device. The image transfer device has a foraminous, image-forming surface comprising a regular pattern of three-dimensional surface elements.

This application is a divisional of U.S. application Ser. No.10/008,736, filed on Dec. 6, 2001, now U.S. Pat. No. 6,564,436, whichclaims benefit of U.S. Provisional Application No. 60/251,683 filed onDec. 6, 2000.

TECHNICAL FIELD

The present invention relates generally to a method of forming alaminate or composite compound textile fabric, and more particularly toa method of overlaying a textile fabric layer with at least one othertextile fabric layer on a three-dimensional image transfer device,whereby the fabric layers are entangled together and a regular patterndefined by the image transfer device is imparted to the compound fabric.

BACKGROUND OF THE INVENTION

Woven textile fabrics, including a plurality of interwoven warp and weftyarns, are used in a wide variety of applications, including apparel,home furnishings, recreational products, and industrial applications.Because of the expense associated with spinning of yarns, and weaving oftextile fabrics, techniques have been developed for manufacture ofnonwoven fabrics from fibrous or filamentary materials. Typically,manufacture of nonwoven fabrics entails creating a web or batt offibrous or filamentary material, and treating the web in a manner toprovide the resultant fabric with the desired physical properties.

The inherent physical performance of a single layer of fabric, whetherwoven or nonwoven, is constrained within the limits of the basis weightfor that material. Should there be a desire for a single fabric layer tohave a higher level of performance, a change in the constituent materialand/or the mode of fabric formation must occur. For example, in order tofabricate a textile fabric with a better uniformity of yarn coverage, itis generally accepted by those skilled in the art that the yarn countmust increase. An increase in yarn count, however, requires that theweaving process have a lower throughput and a corresponding increase incomplexity. When a nonwoven fabric is desired to have improved fibercoverage, typically, additional fiber is used in the web construction,additional cards employed, and complicated air-randomizing orcross-lapping equipment incorporated. Again, a deleterious effect onfabric manufacture and relative costs is realized in making such achange in fabric physical performance.

It has been appreciated in the prior art that a fabric material havingimproved physical performance could be obtained by incorporating one ormore layers of fabric into a unitary construction. Relativelylightweight fabrics, which are much simpler and cost effective toconstruct, but have low inherent physical performance, are placed inface-to-face juxtaposition. In order to form the material into alaminate or composite fabric, a layer of adhesive is interposed at thatinterface. The adhesive has been typically selected from those formsincluding an adhesive spunbond layer, adhesive powder dispersion, or thespray application of a liquid adhesive. The resulting laminate orcomposite fabric, referred to hereafter as a compound fabric, thusexhibits an improved physical performance, however, the adhesive binderadversely affects other physical properties, most notably thedrapeability and the porosity of the compound fabric. Further, theselection of the binder adhesive and the mechanism of application is nota trivial task, requiring significant experimentation to obtaining alaminate or composite fabric exhibiting the best balance of performancecharacteristics.

U.S. Pat. No. 5,136,761, to Sternlieb, et al., attempts to address theissue of forming a composite woven-nonwoven fabric without a binderadhesive by the use of hydroentanglement. The Sternlieb patent disclosesvarious techniques for hydro-enhancing and hydro-patterning fabric,including a hydro-bonded nonwoven and woven fabric composite, but it isbelieved that due to the limitations in imaging techniques disclosed inthis patent, such practice has met with only limited commercial success.

The present invention contemplates a method of forming a textilelaminate or composite fabric from a plurality of woven fabric layers,with the method contemplating use of a three-dimensional image transferdevice to facilitate efficient and commercially viable use of themethod.

SUMMARY OF THE INVENTION

Herein is disclosed a method of forming an imaged textile laminate orcomposite compound fabric, the fabric having a first textile fabriclayer comprising a plurality of interwoven warp and weft yarns and atleast one other textile fabric layer, the lamination of the fabriclayers and imaging of the construct occurring on a three-dimensionalimage transfer device. The image transfer device has a foraminous,image-forming surface comprising a regular pattern of three-dimensionalsurface elements.

A first woven textile fabric used in the construction of the compoundfabric receives thereupon a second textile fabric. The first and secondfabric layers may be of the same or different construction. Thejuxtaposed textile fabric layers are positioned on the image transferdevice, and hydraulic imaging of the fabric effected by subjecting thefabric to pressurized liquid streams applied to a surface of the secondwoven textile fabric facing away from the image transfer device. By theaction of the high-pressure liquid streams, the two textile fabriclayers are entangled and the regular pattern defined by theimage-forming surface of the image transfer device is imparted to theresulting compound fabric. The aesthetic pattern imparted to the fabricmay include an image, which results from rearrangement and displacementof the fabric yarns, to impart a three-dimensionality to the fabric, aswell as patterning which results from differential washing of dyes orcolor from the fabric which corresponds to the pattern of the imagetransfer device.

It is within the purview of the present invention that an intermediatelayer can be interposed between the first and second woven fabric layersprior to hydraulic entanglement on the image transfer device. Theintermediate layer can be selected from those fibrous materialsexhibiting a high loft property, as typified by a polyester or cottonbatting, such that upon lamination and imaging on an image transferdevice having an appropriate three-dimensional pattern, a quilt-likelaminate is formed. In the alternative, an open mesh scrim can beemployed as a reinforcing intermediate layer such that the woven fabricsare able to entangle through the interstices of the scrim layer and forman imaged compound fabric exhibiting low extensibility.

Further, a laminated and imaged compound fabric of the present inventioncan be treated to form a napped surface. A compound fabric formed by thedisclosed lamination procedure results in an entanglement of theconstituent fibers composing the yarns. When the imaged compound fabricis subsequently and purposefully delaminated, those entangled fibers aredrawn perpendicular to the plane of the original surface and elongated.If a constituent fiber is used in the yarn construction that exhibitscrimping upon elongation or stretch, a particularly apparent nappedsurface is obtained.

The present method has been practiced for imparting an image topolyester and polyester/cotton fabrics comprising polyester and blendedpolyester/cotton fibers, respectively. As will be appreciated, thetechnique can be employed for imparting an image to a wide variety ofwoven fabrics. Standard, low cost textile products can be transformedinto high value, three-dimensional fabrics suitable for apparel, homefurnishing, upholstery, and other applications. A fabric that isotherwise substantially uniform in appearance can be provided with anaesthetically pleasing pattern, reflecting the three-dimensionality ofthe fabric and/or color variations therein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of an apparatus for imaging a woventextile fabric embodying the principles of the present invention; and

FIGS. 2-5 are diagrammatic views of the image-forming surface of athree-dimensional image transfer device of the apparatus shown in FIG.1.

DETAILED DESCRIPTION

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred embodiment of the invention, with theunderstanding that the present disclosure is to be considered as anexemplification of the invention, and is not intended to limit theinvention to the specific embodiment illustrated.

Hydroentangling techniques have been developed for manufacture ofnonwoven fabrics whereby patterning and imaging of the fabric can beaffected as the fabric is hydraulically formed on a three-dimensionalimage transfer device. U.S. Pat. Nos. 5,098,764, 5,244,711, 5,822,823,and 5,827,597, the disclosures of which are hereby expresslyincorporated by reference, relate to the use of such three-dimensionalimage transfer devices. Use of these types of devices permits greatlyenhanced versatility in the production of hydroentangled fabrics.

The present invention contemplates durably combining two or more textilefabrics, at the same time an image is imparted into the resultantcompound fabric, by the use of a three-dimensional image transferdevice. Positioning of overlaid, or layered, textile fabrics upon theimage-forming surface of a three-dimensional image transfer device, inconjunction with hydraulic treatment of the fabric, desirably acts toefficiently combine and impart a regular image defined by the imagetransfer device to the compound fabric. Under the influence ofhigh-pressure liquid (water) streams, hydraulic treatment of the wovenfabric layers results in displacement of the interwoven yarns so thatthe fabric is imparted with a patterned image defined by the imagetransfer device. Additionally, imaging of the fabric can be effected asa result of the washing of dyes from the fabric under the influence ofthe high-pressure liquid streams, thus enhancing the three-dimensionalimaging which can be created, or providing a pattern of colordifferentiation which can, in itself, be desirable.

The fabric of the present invention may be used in a wide variety oftraditional textile applications, including apparel, home fashions, andindustrial applications. Apparel applications of the disclosed fabricinclude bottom weights, such as pants and shorts, while home fashionsapplications include, but are not limited to, bedding, window coverings,such as sheers or blinds, and draperies. Industrial applications of thepresent invention include protective covers of outdoor equipment as wellas protective wear.

With reference to FIG. 1, therein is illustrated an apparatus forpracticing the present method for forming a nonwoven fabric. Thecompound fabric is formed from the combination of two or more textilefabrics, shown in roll form at unwind stations 10 and 11. Suitabletextile fabrics include those comprising weaves and knits formed fromyarns comprising fibers. Such fibers may be selected from natural orsynthetic composition, of homogeneous or mixed fiber length. Suitablenatural fibers include, but are not limited to, cotton and viscoserayon. Synthetic fibers, which may be blended in whole or part, includethermoplastic and thermoset polymers. Thermoplastic polymers suitablefor this application include polyolefins, polyamides and polyesters. Thethermoplastics may be further selected from homopolymers, copolymers,conjugates and other derivatives including those thermoplastic polymershaving incorporated melt additives or surface-active agents. The profileof the fiber is not a limitation to the applicability of the presentinvention.

It is within the purview of the present invention that a scrim can beinterposed between the textile fabric layers. The purpose of the scrimis to reduce the extensibility of the resultant three-dimensional imagedcompound fabric, thus reducing the possibility of three-dimensionalimage distortion and further enhancing fabric durability. Suitablescrims include unidirectional monofilament, bidirectional monofilament,expanded films, open meshes and thermoplastic spunbond.

The compound fabric has also been found to yield an interesting productwhen the textile fabric layers are purposefully delaminated from thecompound fabric. As the entangled layers are drawn away from oneanother, the constituent fibers of the bloomed yarns elongate and eitherdisentangle or break. The newly freed fiber ends tend to create acrimped presentation and were found to maintain a z-directionorientation. Conversely, the other end of the constituent fibersremained entrained in the woven yarn and provided a durable presentationof the pile to abrasion. It is envisioned that a high speed pileformation process embodying the present invention whereby the compoundfabric is then delaminated is a reasonable alternative to eitherspecially woven fabrics with z-directional yarns that require shearingor the use of teasel combs and brushes on substantially planar fabrics.

EXAMPLES Example 1

Using a forming apparatus as illustrated in FIG. 1, a compound fabricwas made in accordance with the present invention by providing a firsttextile fabric annotated as “WL1” at unwind station 11 and secondtextile fabric annotated as “WL2” at unwind station 10. The textilefabric used on both unwind stations was a woven 50% polyester/50% cottonfabric of 120 thread count. The textile fabrics were unwound at anequivalent rate and positioned in face-to-face juxtaposition then wettedand lightly entangled at pre-entanglement station 15. Thepre-entanglement station 15 includes a foraminous forming surface in theform of belt 12 upon which the overlaid textile fabrics are positionedfor pre-entangling by entangling manifolds 14. In the present examples,each of the entangling manifolds 14, included 120 micron orifices spacedat 42.3 per inch, with the manifolds successively operated at 100, 300,and 1500 pounds per square inch, with a line speed of 35 feet perminute. The entangling apparatus of FIG. 1 further includes an imagingdrum 18 comprising a three-dimensional image transfer device foreffecting imaging of the pre-entangled layered fabric construct. Theimage transfer device includes a moveable imaging surface which movesrelative to a plurality of imaging manifolds 22 which act in cooperationwith three-dimensional elements defined by the imaging surface of theimage transfer device to effect imaging and patterning of the fabricbeing formed. The imaging manifolds 22 includes 120 micron orificesspaced at 42.3 per inch, with the three manifolds operated at 3500pounds per square inch each. The imaged compound fabric was dried usingtwo stacks of steam drying cans at 300° F.

The particular image transfer device used was a 100 mesh pattern wherebyper one inch square there are one hundred MD and one hundred CDinterwoven metal wires.

Example 2

Using the apparatus described in Example 1, a compound fabric wasfabricated whereby in the alternative a 0.5 ounce carded web of 1.2denier polyester was interposed between the 120 thread count wovenlayers. The entangling manifolds 14 were operated at successivepressures of 100, 300, 1000, and 1500 pounds per square inch. Theimaging manifolds were operated at 4500 pounds per square inch. Overallline speed was maintained at 35 feet per minute. The image transferdevice included four different regions, each region corresponding toFIGS. 2, 3, 4 and 5.

Example 3

Using the apparatus described in Example 1, a compound fabric wasfabricated whereby in the alternative a 3.5 ounce carded web of 3 denierpolyester was interposed between the 120 thread count woven layers. Theentangling manifolds 14 were operated at successive pressures of 100,300, 1000, and 1500 pounds per square inch. The imaging manifolds wereoperated at 4500 pounds per square inch. Overall line speed wasmaintained at 35 feet per minute. The image transfer device includedfour different regions, each region corresponding to FIGS. 2, 3, 4 and5.

Example 4

Using the apparatus described in Example 1, a compound fabric wasfabricated whereby in the alternative a 1.0 ounce thermal point bondedpolyester spunbond was interposed between the 120 thread count wovenlayers. The entangling manifolds 14 were operated at successivepressures of 100, 300, 1000, and 1500 pounds per square inch. Theimaging manifolds were operated at 4500 pounds per square inch. Overallline speed was maintained at 35 feet per minute. The image transferdevice included four different regions, each region corresponding toFIGS. 2, 3, 4 and 5.

From the foregoing, numerous modifications and variations can beeffected without departing from the true spirit and scope of the novelconcept of the present invention. It is to be understood that nolimitation with respect to the specific embodiment illustrated herein isintended or should be inferred. The disclosure is intended to cover, bythe appended claims, all such modifications as fall within the scope ofthe claims.

Test Procedures

Grab Tensile Test (ASTM D 5034)

This test is meant to measure the breaking strength of the fabric inunits of either grams or pounds as well as measures the elongation ofthe fabric.

Drape (INDA IST 90.0-75 R82)

A Handle-o-Meter is utilized to measure the flexural resistance of thefabric. The Handle-o-Meter records the grams of force required for themoveable beam to displace the fabric through a slot with a predeterminedwidth.

Mullen Burst (ASTM D 461)

This test measures the pressure (psi) required to rupture the fabricwhen pressure is increased at a controlled constant rate.

Elmendorf Tear (ASTM D 5734)

The Elmendorf Tear determines the force in grams required to tear asample after the tear has been initiated, which provides a measure ofinternal tearing resistance as distinguished from the initial tearingresistance.

A sample of the compound fabric from Example 1 was placed in an InstronTensile test device with the bottom face of the compound fabric affixedby clamp to base of the Instron and upper face affixed by clamp to themovable platform. The moveable platform was then operated at constantrate to move away from the base, thus purposefully delaminating thecompound fabric. A pronounced yet durable pile formation was noted.

The compound fabric from Example 4 was tested and compared to anothercompound fabric as in Example 4, less one 120 thread count woven layer.As illustrated in Table 1, the tri-layered compound fabric as describedin Example 4, was more than two times stiffer than the bi-layeredcompound fabric.

TABLE 1 Elong. @ Basis Mullen Tensile @ Peak- Tensile @ Elong. @Handle-o- Handle-o- Elmendorf Elmendorf Weight Burst Peak-MD MD Peak-CDPeak-CD Meter-CD Meter-MD Tear-MD Tear-CD ITD (osy) (psi) (lb) (%) (lb)(%) (grams) (grams) (grams) (grams) single no ITD 3.97 104  69 13 38 33153 43 892 1305 layer of 120 ct. woven plus a layer of SBPET Sm. seg-4.06 59 15 39 34 50 153 638 1013 mented diamond Lg. seg- 4.06 68 16 3931 49 150 662 963 mented diamond Small 4.06 64 15 37 31 52 159 651 1007squares Large 4.06 67 15 39 29 59 176 532 922 squares two no ITD 6.85194  129 18 82 28 644 297 1872 2370 layers of 120 ct. woven plus amiddle layer of SBPET Sm. seg- 7.16 200+ 136 19 82 36 256 722 1261 1794mented diamond Lg. seg- 7.15 200+ 138 18 85 32 264 722 1363 1823 menteddiamond Small 7.16 200+ 139 17 74 32 293 717 1284 1819 squares Large7.16 200+ 135 17 79 32 260 723 1007 1819 squares

1. An article, comprising: a plurality of coaffixed fabric panels, oneor more of the fabric panels comprising a first fabric layer and asecond fabric layer, said first and second fabric layers being formedfrom textile yarns, said first fabric layer and said second fabric layerbeing hydraulically bonded and imaged with a three-dimensional patterncorresponding to a pattern of a three-dimensional image-transfer device.2. An article in accordance with claim 1 wherein: said first fabriclayer and said second fabric layer are each selected from the groupconsisting of woven fabrics, knitted fabrics, and the blends thereof. 3.An article in accordance with claim 1, wherein: a article is selectedfrom the group consisting of a bottom weight garment, a home fashionarticle, and a protective cover.
 4. An article, comprising: a pluralityof co-affixed fabric panels, one or more of the fabric panels comprisinga first fabric layer, a fibrous intermediate layer, and a second fabriclayer, said first and second fabric layers being formed from textileyarns, said first fabric layer and said second fabric layer beinginterposed with the fibrous intermediate layer and hydraulically bondedand imaged with a three-dimensional pattern corresponding to a patternof a three-dimensional image-transfer device.
 5. An article inaccordance with claim 4, wherein: a article is selected from the groupconsisting of a bottom weight garment, a home fashion article, and aprotective cover.